US20100028190A1 - Method of making powder metal parts using shock loading - Google Patents

Method of making powder metal parts using shock loading Download PDF

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US20100028190A1
US20100028190A1 US12/183,151 US18315108A US2010028190A1 US 20100028190 A1 US20100028190 A1 US 20100028190A1 US 18315108 A US18315108 A US 18315108A US 2010028190 A1 US2010028190 A1 US 2010028190A1
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mixtures
titanium
component
mixture
mold
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Yucong Wang
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GM Global Technology Operations LLC
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GM Global Technology Operations LLC
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Priority to DE102009034969A priority patent/DE102009034969A1/de
Priority to CN2009101596980A priority patent/CN101637822B/zh
Assigned to GM GLOBAL TECHNOLOGY OPERATIONS, INC. reassignment GM GLOBAL TECHNOLOGY OPERATIONS, INC. RELEASE BY SECURED PARTY (SEE DOCUMENT FOR DETAILS). Assignors: CITICORP USA, INC. AS AGENT FOR BANK PRIORITY SECURED PARTIES, CITICORP USA, INC. AS AGENT FOR HEDGE PRIORITY SECURED PARTIES
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/045—Alloys based on refractory metals
    • C22C1/0458—Alloys based on titanium, zirconium or hafnium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/05—Mixtures of metal powder with non-metallic powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24—After-treatment of workpieces or articles
    • B22F2003/247—Removing material: carving, cleaning, grinding, hobbing, honing, lapping, polishing, milling, shaving, skiving, turning the surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps

Definitions

  • the present invention relates generally to using powder metallurgy to produce reinforced titanium-based structures, and more particularly to making titanium alloy metal matrix composite-based components for automotive and other transportation applications.
  • PM Powder metallurgy
  • titanium alloys have desirable structural properties, such as high specific strength and excellent corrosion resistance, they are particularly well-suited for automotive applications, including valves, retainers, valve springs, connecting rods in the engine and drivetrain and half shafts, bolts and fasteners, coil suspension springs and exhaust system in the body and chassis.
  • Reinforcement such as particle reinforcement, can be used to further their structural properties, such as elastic modulus (a measure of rigidity), wear resistance and heat resistance.
  • Titanium diboride (TiB 2 ) particles are commonly used as such particle reinforcement, and PM is one way to achieve particle reinforcement with TiB 2 in a cost-effective way, although other ceramic reinforcing materials, such as titanium carbide (TiC) or titanium nitride (TiN) could also be used.
  • a method of making a powder metal component where, in one form, the part is made from a Ti-6Al-4V/TiB MMC by powder metallurgy, and in a more particular form, the part is compacted by shock loading.
  • shock loading powder compaction compared to conventional pressing methods
  • original powder properties can be maintained in the compact, alloys can be produced with unique compositions, and non-stoichiometry compositions and non-equilibrium structures can be fabricated.
  • densities of the finished parts approach that of theoretical densities, often exceeding ninety nine percent.
  • the component may be a composite made from a titanium alloy matrix and TiB 2 reinforcement particles dispersed within the matrix.
  • the TiB 2 reacts with the elemental titanium during sintering to produce TiB (the reinforcing particulate in the as-manufactured MMC), which is only thermodynamically stable in the titanium alloy.
  • Sintering which involves heating the material to a temperature slightly below its melting point such that the disparate particles of the precursor materials in the mixture adhere to one another by solid-state diffusion.
  • the sintering may preferably be performed in a controlled atmosphere to avoid oxidation and related contamination.
  • titanium matrices there are certain alloys that have demonstrated particular suitability for structural components such as those encountered in aerospace and automotive applications. These include beta titanium, alpha-2 titanium, gamma titanium and combinations thereof.
  • beta titanium which may be used in the present invention include titanium with approximately six weight percent aluminum and approximately four weight percent vanadium (i.e., referred to herein as Ti-6Al-4V, and elsewhere as Ti 6-4), and titanium with approximately six weight percent aluminum, approximately two weight percent tin, approximately four weight percent zirconium and approximately two percent molybdenum (i.e., Ti 6-2-4-2).
  • Ti-6Al-4V is especially useful in the manufacture of composite-reinforced automotive components, based on its relative abundance, chemical compatibility and ease of processing. Furthermore, TiB 2 is a particularly compatible reinforcement for Ti-6Al-4V based composites.
  • the component is a connecting rod used in aviation, marine, automotive and related internal combustion engines.
  • automotive is intended to refer to not only cars, but trucks, motorcycles, buses and related vehicular modes of transportation. In engine-related applications, high mechanical loading and high temperatures are both in existence.
  • Other examples of automotive component where the present method and titanium-based MMC may find beneficial use includes valves, retainers, valve springs, bolts, fasteners, coil suspension springs and exhaust systems.
  • placing the one or more mixtures into a mold includes selectively placing one of the mixtures into a first region within the mold while selectively placing another of the mixtures into a second region within the mold.
  • the portion of the component corresponding to the first region is made up almost entirely of the first of the mixtures
  • the portion of the component corresponding to the second region is made up almost entirely of the second mixtures of the mixtures, where it will be understood that in regions that bridge two disparate regions together generally correspond to a transition region made up of a blend of the mixtures from the adjoining regions.
  • a source of the shock loading is selected from the group consisting of mechanical (for example, compressed spring), electrohydraulic, electromagnetic, piezoelectric and explosive means. More particularly, the explosive means is selected from the group consisting of explosive shock loading and electric gun shock loading. In yet another option, post-sintering machining may be performed on the component.
  • a method of making a titanium-based MMC component includes defining numerous regions within a mold, arranging more than one mixture of a titanium alloy-based matrix and a titanium-based ceramic reinforcement so that each of the mixtures has a different matrix-to-reinforcement ratio than the other mixtures, placing a first of the mixtures into a first of the regions, placing a second of the mixtures into a second of the regions, compacting the various mixtures in the mold by shock loading, removing the component from the mold and sintering the component.
  • the mold is substantially shaped in the form of the component.
  • the term “substantially” refers to an arrangement of elements or features that, while in theory would be expected to exhibit exact correspondence or behavior, may, in practice embody something slightly less than exact.
  • the term denotes the degree by which a quantitative value, measurement or other related representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue.
  • the shock loading functions in such a way that upon the compacting, the portion of the component corresponding to the first region substantially contains the first mixture, while the portion of the component corresponding to the second region substantially contains the second mixture.
  • the matrix is one of beta titanium, alpha-2 titanium, gamma titanium and combinations thereof.
  • the reinforcement comprises a ceramic, a particular version of which is TiB 2 .
  • post-sintering operations are performed on the component, such as machining.
  • the component being made is a connecting rod.
  • the first of the numerous mixtures contains a lower concentration of reinforcing phase than the second of the mixtures.
  • the portion of the connecting rod that corresponds to the first of the mixtures has a lower structural or loading requirement than the portion of the connecting rod that corresponds to the second of the mixtures. Examples of such structural or loading requirement include strength, stiffness and related measure of a material's or component's load-bearing capability.
  • a method of making a titanium-based MMC connection rod for an internal combustion engine includes combining a titanium alloy-based matrix and a titanium-based ceramic reinforcement into a plurality of mixtures such that each of the mixtures has a different matrix-to-reinforcement ratio than the others.
  • the method further includes placing a first of the mixtures into a first region of a connecting rod mold, placing a second of the mixtures into a second region of the connecting rod mold, compacting the mixtures in the connecting rod mold by shock loading, removing the connecting rod from the mold than sintering the compacted plurality of mixtures in such a way as to form the connecting rod.
  • the connecting rod substantially comprises a Ti-6Al-4V/TiB 2 MMC.
  • the shock loading is accomplished through movement of a compaction member (for example, a piston) in response to a shock source selected from the group consisting of a compressed spring, an electrohydraulic device, an electromagnetic device, a piezoelectric device, an explosive device and an electric gun.
  • a compaction member for example, a piston
  • a shock source selected from the group consisting of a compressed spring, an electrohydraulic device, an electromagnetic device, a piezoelectric device, an explosive device and an electric gun.
  • the compacting takes place under high speed and high pressure shock waves in less than one second, more particularly in a fraction of a second, and more particularly, fewer than ten microseconds.
  • FIG. 1 shows a process route flowpath for producing a titanium-based MMC component according to an aspect of the present invention
  • FIG. 2 shows a shock wave generation device used to produce the shock loading according to an aspect of the present invention
  • FIG. 3 shows a connecting rod made according to an aspect of the present invention, including various discreet regions where differing TiB 2 concentration levels may be placed;
  • FIGS. 4A through 4F show the impact of varying amounts of TiB 2 additions to Ti-6Al-4V/TiB MMC microstructures.
  • a process route flowpath for producing a titanium-based MMC component includes blending 10 of various constituent powders 10 A, 10 B to 10 N that correspond to the number of materials needed to make up the MMC.
  • constituent powders 10 A to 10 N may include separate titanium, titanium hydride, aluminum-vanadium, TiB 2 and other powders.
  • additional constituents such as binders, lubricants or the like may also be included into the mixture produced by blending 10 , although such binders and lubricants are not necessary.
  • the blending 10 may be followed by a milling and activation step 20 , followed by close die compaction via shock loading 30 and then sintering 40 to produce the finished part.
  • a vacuum for example, about 10 ⁇ 3 Pa for a period between two and eight hours, with a more specific range of three to six hours
  • sintering times can further improve the sintered density.
  • Additional post-sintering steps may also be employed, including machining 50 . Numerous examples of such machining 50 and related operations are possible, including deburring, surface compressive peening, repressing or the like.
  • oxidation-prevention steps may be employed, such as through the addition of an oxide or related coating like Al 2 O 3 , SiO 2 and B 2 O 3 if hot forging is used after sintering.
  • shock loading also called shock compaction or shock loading impaction
  • the shock waves can be produced by electrohydraulic, electromagnetic, piezoelectric and explosive means. Electrohydraulic initiation of the shock waves produces higher energy flux density than the electromagnetic and piezoelectric variants.
  • the explosion initiation includes explosive shock loading and electric gun shock loading; in the former, high explosives, such as trinitrotoluene (TNT), are used, while in the latter, a thin dielectric flyer is accelerated toward the powder assembly as a result of exploding, or vaporizing, a thin metallic foil.
  • the electric gun uses the energy initially stored in a capacitor bank to ohmically heat and explode, or vaporize, a thin, metallic (e.g., aluminum) foil on a folded transmission line laminate.
  • shock loading is used to produce a dense solid from precursor powders.
  • shock loading can be used to compact polymeric powders or a combination of the above.
  • the powders which are generally at room temperature prior to initiation of the shock wave, are compacted by a shock front that travels through the encapsulated powders.
  • shock front that travels through the encapsulated powders.
  • a high-strain rate deformation is established, which tends to cause the material to deform plastically with a lot of localized heat generation.
  • the heat may even melt the particle surface locally due to adiabatic effect, as there may not be enough time for heat dissipation through heat transfer.
  • shock waves are used to produce high velocity impact (several to several hundred meters per second) at high pressure and in a very short time (for example, on the order of several microseconds). Unlike conventional PM approaches, no binder is necessary. As such, shock loading has the benefit of increasing the green part density (for example, to 99% or more).
  • Planar shock waves are preferred for their ability to provide controlled waves and concomitant maximum and uniform compaction through the part being compacted.
  • the explosives are initiated at the top of the assembly by a detonator; this causes shock waves to run down the length of the powders.
  • the shock front produced by detonating explosive compacts the encapsulated powders to a solid form.
  • the pressure exerted by the shock front is usually several times greater than the shear stress of powders being compacted. This causes plastic deformation of the powders and the densification of the compact due to the plastic flow of the material and collapsing of voids.
  • Particle-particle friction, deformational heat, and high velocity impact of individual particles caused by the shock front lead to the bonding of the particles to adjacent particles.
  • Compacts with a high density, close to theoretical, can be fabricated using the explosive compaction method.
  • Advantages of explosive powder compaction include that the process is not limited to small scale applications, original powder properties can be maintained in the compact, alloys can be produced with unique compositions, and non-stoichiometry compositions and non-equilibrium structures can be fabricated, densities approach that of theoretical densities.
  • Compaction device 300 includes a shock housing 310 , where a compaction member (presently shown in the form of a piston 320 , although capable of existing in another form) reciprocates up and down in a chamber 330 formed in the housing 310 .
  • An upper die 340 A and a lower die 340 B have shapes that cooperate so that when the dies 340 A and 340 B are brought into engagement with one another, a mixture containing one or more of the powders 10 A, 10 B . . . 10 N is compacted into a shape dictated by the cooperating dies 340 A and 340 B.
  • explosive powder compaction (or one of the other shock loading approaches) can be used to impart enough energy to piston 320 to force compaction of the powder mixture resident between the dies 340 A and 340 B.
  • shock wave to push the piston 320 and upper die 340 A (which may be formed together as an assembly) to impact the powder 10 A, 10 B . . . 10 N that is placed in the compaction shape between the dies 340 A and 340 B.
  • the first is through a spring-piston gun (not shown), where by releasing a compressed coiled steel in the gun, the piston 320 is pushed forward. This takes place in a fraction of a second, during which the air between the assembly made up of the piston 320 and upper die 340 A undergoes adiabatic heating to several hundred degrees during compression.
  • the powders are compacted by a shock front that travels through the encapsulated powders.
  • shock waves Under high speed and high pressure shock waves in a very short time, a material tends to deform plastically with a lot of heat generated locally. The heat may even melt the powder material locally due to the adiabatic effect, as there is not enough time for heat dissipation through heat transfer. Plastic deformation of the powder is caused by the high-strain rate deformation, and can even occur in ceramic materials.
  • the shock waves produce high velocity impact (10-1000 m per second) at high pressure and in a very short time.
  • Other methods to produce impact include electrohydraulic, electromagnetic and piezoelectric, as discussed above.
  • the entire shock loading process uses one stroke, one die and produces one or multiple parts. However, multiple strokes are possible with means other than explosive shock loading.
  • the component Once the component has gone through the shock loading, it can be sintered to further improve its density and strength.
  • a Ti-6Al-4V-based connecting rod with ten percent (by weight) TiB 2 the part is heated at a rate of two to five degrees Celsius per minute, within a temperature range of between 1200 degrees Celsius and 1450 degrees Celsius for between two and eight hours.
  • an average sintering temperature is about 1300 degrees Celsius, with a typical sintering time of about three hours.
  • Typical sintering vacuum is in the range of 10 ⁇ 3 Pascals. Longer sintering times can significantly improve the sintered density.
  • a cooling schedule may be used, where the sintered and compacted component is cooled over the course of numerous hours.
  • connecting rod 100 made according to the present invention is shown.
  • the rod 100 is used in automotive engines, acting as the joining element between a piston and a crankshaft (neither of which are shown) to transfer the rotary motion of the latter into a linear, reciprocating motion in the former.
  • the top 110 of connecting rod 100 includes an exaggerated end 115 with a journal or bearing region 117 therein that houses wrist pin bushings (not shown), while the bottom 120 includes an even larger exaggerated end 125 with a journal or bearing region 127 therein that houses crankshaft bearings (not shown).
  • Bolts 128 or related fasteners secure a bearing cap 129 to exaggerated end 125 that may include a small port (not shown) to allow the flow of motor oil or related pressurized lubricant to the piston.
  • a neck region 130 extends between the ends 115 and 125 , connecting the two together in a substantially unitary configuration. Connecting rod 100 is subject to extreme tensile, compression and bending stresses, and as such, has special requirements on its mechanical properties and machinability.
  • the neck region 130 should have very high stiffness, tensile and compression yield strength, as well as fatigue resistance to ensure the high performance and durability, while the regions 117 and 127 within the respective housing ends 115 and 125 require precision machining.
  • the concentration of the reinforcing TiB 2 can be tailored to the particular regions within the connecting rod 100 .
  • the neck region 130 and at least the non-journalled part of the bottom region 120 can be made from a higher concentration of reinforcing phase material, for example, ten weight percent TiB 2 particle reinforcement.
  • These regions require higher stiffness, while generally involving only minimal machining. As such, they are good candidates for the harder, stiffer MMC produced by larger concentrations of TiB 2 particles.
  • the portion associated with cap 129 while made from the lower TiB 2 particle concentration, can employ sacrificial metal rods in order to form the bolt holes therein. Sacrificial (either metallic or nonmetallic) mandrels can be used to make the necessary holes.
  • the journal or bearing region 117 of the top housing end 115 and the journal or bearing region 127 of bottom housing 125 can be made from lower reinforcing phase material concentrations, for example, between five and seven weight percent TiB 2 particle reinforcement.
  • journals or bearings require a lot of machining, and the lower TiB 2 content in the MMC makes it easier to machine, resulting in a much lower machining cost, as the machining productivity and related tool life are improved.
  • the filling of the blended powders with different TiB 2 compositions into different die regions can be achieved through multiple sequences. In such an approach, while individual regions (such as regions 117 , 127 and 130 ) are being filled with the powder, the other regions are blocked. In this way, different regions within a particular component can have differing levels of reinforcement placed to provide tailored properties. After the filling, the close die compaction is conducted at room temperature to make a compacted green (i.e., pre-sintered) part.
  • Such a tailored design made possible by placement of specific TiB 2 concentrations in discreet component locations would provide great flexibility for the optimization of mechanical property and machining ability of connecting rod 100 .
  • the various regions 117 , 127 and 130 can be separately filled with the particle/matrix mixture.
  • various transition regions will form between these discreet regions of differing particle concentration; these transition regions can have a gradient composition microstructure and gradient mechanical properties.
  • the typical sizes of the titanium powders used for making metal matrix composite (MMC) precursor powder can be in the range of two and one hundred and fifty micrometers, which is much wider than those in the conventional powder metal compaction.
  • the typical TiB 2 particle size and Al—V master-alloy powder are each in the range of five to seventy five micrometers. It will be appreciated by those skilled in the art that there are several possible methods for producing these powders.
  • the titanium powder can be made by the well-known hydride-dehydride process.
  • FIGS. 4A through 4F the sintered microstructures of the Ti-6Al-4V/TiB 2 MMC with zero, three, seven, ten, fifteen and twenty weight percent TiB 2 reinforcing phases are shown.
  • the grain size in the microstructures becomes smaller with the increased TiB 2 content.
  • An increase in reinforcing phase TiB (where TiB 2 becomes a TiB phase in the alloy) and reduced grain size explains the increased tensile and yield strength and stiffness.
  • elongation decreases with the increased TiB 2 content.
  • TiB 2 is an excellent reinforcement for Ti-6Al-4V titanium alloy.
  • the Ti-6Al-4V MMC has higher strength and elastic modulus.
  • the elastic modulus of the reinforced Ti-6Al-4V is over 140 GPa, with over 155 GPa in comparison with 100 GPa average for unreinforced Ti-6Al-4V.
  • the ultimate tensile strength of over 1350 MPa (average 1450 MPa) is significantly greater than the 1100 MPa average for the unreinforced Ti-6Al-4V, with a 0.2% yield strength of over 1250 MPa (average 1300 MPa), in comparison with average of 1050 MPa for unreinforced Ti-6Al-4V.
  • the Rockwell hardness is above forty three.

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  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
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US12/183,151 2008-07-31 2008-07-31 Method of making powder metal parts using shock loading Abandoned US20100028190A1 (en)

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DE102009034969A DE102009034969A1 (de) 2008-07-31 2009-07-28 Verfahren zur Herstellung von Pulvermetallteilen mithilfe von Stoßbelastung
CN2009101596980A CN101637822B (zh) 2008-07-31 2009-07-31 使用冲击加载制造粉末金属部件的方法

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US20090314246A1 (en) * 2008-06-24 2009-12-24 Gerald Martino Titanium connecting rod
US20110214529A1 (en) * 2008-06-24 2011-09-08 Gerald Martino Machined Titanium Connecting Rod and Process
CN102193502A (zh) * 2011-06-14 2011-09-21 中南大学 一种钢铁烧结二次配料的综合优化方法
US20160209111A1 (en) * 2015-01-15 2016-07-21 Pepsico, Inc. Beverage cooling
US20180194196A1 (en) * 2017-01-06 2018-07-12 GM Global Technology Operations LLC Systems and methods utilizing heat pumps to recover thermal energy from exhaust gas
US10385415B2 (en) 2016-04-28 2019-08-20 GM Global Technology Operations LLC Zinc-coated hot formed high strength steel part with through-thickness gradient microstructure
US10619223B2 (en) 2016-04-28 2020-04-14 GM Global Technology Operations LLC Zinc-coated hot formed steel component with tailored property
CN114750478A (zh) * 2022-04-14 2022-07-15 中国工程物理研究院流体物理研究所 一种同心双阻抗组合飞片及其制备工艺、应用
US11530469B2 (en) 2019-07-02 2022-12-20 GM Global Technology Operations LLC Press hardened steel with surface layered homogenous oxide after hot forming
US11613789B2 (en) 2018-05-24 2023-03-28 GM Global Technology Operations LLC Method for improving both strength and ductility of a press-hardening steel
US11612926B2 (en) 2018-06-19 2023-03-28 GM Global Technology Operations LLC Low density press-hardening steel having enhanced mechanical properties

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CN102133641B (zh) * 2011-04-19 2012-10-24 广州有色金属研究院 一种Ti-6Al-4V合金的粉末冶金方法
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